Note: Descriptions are shown in the official language in which they were submitted.
43955 CAN lA
Z~ 8
HIGH TEMPERATURE RESISTANT OIL BOOM FLOTATION CORE
Field of the Invention
The present invention relates generally to
floating oil containment booms, and particularly those
which allow the in-situ burning of contained oil.
Background of the Invention
The present invention relates to a high temper-
ature resistant flotation core and to a high temperatureresistant oil containment boom constructed therefrom which
allows for the in-situ burning of spilled or leaked oil
during offshore oil spill cleanup operations. In-situ
burning represents one of the most effective means of
eliminating large quantities of spilled oil. If conducted
properly, with due consideration for the temporary
reduction of air quality and the potential for exposure to
fire, the in-situ burning of an oil spill can result in the
least overall impact to the environment.
The remoteness of many oil exploration,
production, and transportation activities (e.g., Alaska),
combined with the nature of the environment, provides ideal
conditions for in-situ combustion. When considered in
conjunction with mechanical cleanup, chemical dispersants,
and natural elimination processes, burning often provides
an important option when some of the other techniques alone
are impractical. For this reason, the oil industry in
Alaska and in Canada has conducted numerous research
efforts to identify the most efficient means of burning oil
in place (Shell Oil Company et. al., 1983; S. L. Ross
Environmental Research Limited, 1983).
Such research has revealed that oil can be
ignited and combustion sustained when the oil layer on
water is at least 1 to 2 mm thick. As thicknesses increase
beyond this minimum value, there is less tendency for heat
loss to the underlying water, and therefore the chances are
greater for efficient combustion. Thick oil layers have
been consistently burned with efficiencies in excess of
-2- 2~7918
95%, even under artic conditions. To achieve such success
through burning, it is important to concentrate any spilled
oil as quickly as possible and to contain the burning oil
so that winds and/or currents can help thicken the oil
slick. During the burning process, temperature in the
order of 1200C is common.
Conventional oil containment booms are elongated
cylinders having a generally circular cross-section. These
booms float in water with approximately one-third of the
boom submerged below the surface of the water forming a
floating barrier to the spilled oil. The booms are
typically stored in a roll on the deck of a ship and
deployed downwind of a spill where it floats on the surface
of the water and temporarily contains the spill.
U.S. Patent No. 4,537,528 is directed to a
fireproof boom core containing a flammable pollutant on a
water surface, the boom comprising a flotation member of
foamed polypropylene and at least two layers of heat-
resistant, water-sorbent material surrounding the flotation
member and extending into the water in the form of a
depending skirt. The skirt functions to draw water up into
the layers of heat-resistant material forming steam in the
presence of flaming pollutant thereby allowing only the
outer layer of heat-resistant material to become slightly
singed. It is understood that a bottom-tensioned,
cylindrical-flotation fire containment boom is manufactured
by Fire Control Inc. utilizing the teachings of said
patent. The boom consists of multiple layers of
fire-resistant, wicking fabric positioned over steel
canisters for flotation. An additional sacrificial layer
and a coarse, wire-mesh barrier are used externally for
abrasion resistance.
U.S. Patent No. 4,619,553 discloses an oil boom
system which utilizes a multilayered, fire-resistant
blanket, and is manufactured by Minnesota Mining and
Manufacturing Company (3M), the assignee of the present
invention. The fire-resistant blanket is used as an add-on
-3- Z~'7918
high temperature protective blanket to convert most
conventional types of booms to a containment for burning
oil. The blanket is placed about the periphery of the boom
and is held in position by any number of fastening systems.
Another oil boom system provided by 3M is a high
temperature oil containment boom which allows for the
in-situ burning of spilled or leaked oil. The boom
comprises an outer layer of polymer coated fabric, a first
underlayer of high temperature resistant refractory fabric
and a second underlayer of a high or intermediate
temperature resistant refractory fabric which constrains
and assists in retaining the integrity of a low density,
high temperature resistant core. The layers are unified by
sewing with high temperature resistant, ceramic thread or
by mechanical fasteners.
Still another oil boom system provided by 3M is a
redeployable high temperature resistant oil containment
boom containing a cellular core. The oil containment boom
comprises an outer layer of polymer coated fabric, a first
underlayer of stainless steel mesh and a second underlayer
of a high or intermediate temperature resistant refractory
tight weave hybrid ceramic textile fabric, all of which
surround and encase a cellular, high temperature resistant
flotation core of inorganic spheres or granules contained
and rolled in a stainless steel mesh. The layers are
unified by sewing with high temperature resistant ceramic
thread or mechanical fasteners.
Problems associated with the above mentioned fire
containment oil booms are that they are either difficult to
recover or are not reusable and some are not redeployable
in the event it was found unnecessary to burn the oil.
Furthermore, those which depend upon wicking to function
often can plug because of contamination by silt or salt
water. Even those which do not depend upon wicking to
function, such as the latter mentioned boom which contained
a cellular core, tended to lose as much as fifty percent of
_4_ 2~9~91~
its buoyancy during use. These problems lead to less than
desirable pe~formance.
Summary of the Invention
The present invention relates to a high temper-
ature resistant flotation core and to a high temperature
resistant oil containment boom constructed therefrom which
allows for the in-situ burning of spilled or leaked oil
and, in the event that the contained oil is not burned, the
boom can be recovered, cleaned in the same manner as a
conventional oil containment boom and stored for future
deployment. The boom is capable of withstanding sustained
exposure to temperatures of 1200C, thus allowihg in-situ
burning of the contained oil during offshore oil spill
cleanup operations. The oil boom can also be employed as a
precautionary measure during traditional oil spill cleanup
operations to provide protection should accidental ignition
of the spilled oil occur. In this situation, the boom
would, of course, be recovered and processed for
redeployment.
The oil boom of the present invention comprises
an outer layer, a first underlayer of knitted wire mesh, a
second underlayer of high temperature resistant refractory
fabric and a heat insulating spacer surrounding a novel
high temperature resistant flotation core. The layers are
unified by sewing with high temperature resistant ceramic
thread, metal thread or mechanical fasteners.
The novel high temperature resistant flotation
core comprises a closed cell foam log covered by a high
temperature resistant knitted wire mesh and optionally
covered by a metal foil. The flotation core with the
optional metal foil covering is preferred.
Brief Description of the Drawing
The drawing is a perspective view, partially in
section, of the high temperature resistant flotation core
and oil containment boom of the present invention.
2t~7~ ~
Description of the Preferred Embodiment
The invention can best be understood by reference
to the drawing. The high temperature resistant oil
containment boom 10 is comprised of outer layer 11 of
polymer coated fabric, a first underlayer 12 of knitted
wire mesh, a second underlayer 13 of high temperature
resistant, refractory tight weave hybrid ceramic textile
fabric and a heat insulating spacer 14, all of which
surround anZ encase a high temperature resistant flotation
core 15. Water line 16 shows that the oil containment boom
10 floats on the water with approximately 30% of the boom
below the surface.
Polymer coated fabric outer layer 11 is
preferably nylon fabric coated with low alkali content
polyvinylchloride (PVC). Other fabrics and polymer
coatings may be used. Examples include polyester fabric
and polyurethane coatings. Outer layer 11 of this
invention allows the high temperature oil boom to be
conveniently handled and function, if desired, as a
conventional non-fire oil containment boom. Outer layer
11, during fire containment, melts to the water line 16
causing the underlayer 12 and 13 to be exposed to the
burning oil. Outer layer 11, may also, if desired, be
provided with a ballast chain pocket 17.
The first underlayer 12 is a knitted wire mesh
made of stainless steel, inconel, steel, galvanized steel
or other suitable alloys. A preferred knitted wire mesh is
310 stainless steel (available from Metex Corporation)
having a wire diameter of about 250 micrometers with
knitted opening sizes corresponding to a density of 60.
The density number relates to the spacing of the needles on
the knitting machine and is well known in the industry.
A high temperature resistant refractory fabric
13 is preferably a 0.64 mm thick open mesh, tight weave, 3
35 x 3 picks/cm ceramic/metal hybrid (85% ceramic/15%
refractory metal wire) fabric woven from 2000 denier, 1/2
-6- z~79~8
served continuous polycrystalline ceramic fiber yarn
comprising, by weight, 70% aluminum oxide, 2% boron oxide
and 28% silicon dioxide (commercially available as Nextel
440 fibers and fabrics from 3M) and 304 stainless steel
S wire. The specific fabric 13 has a basis weight of 0.37
kg/m2. Other fabrics which can be used as high temperature
resistant fabric 13, provided they are similarly woven,
include fabrics fabricated from Nextel 312 ceramic yarn
comprising, by weight, 62~ aluminum oxide, 24% silicon
dioxide and 14% boron oxide (3M), Astroquartz ceramic
fibers (J. P. Stevens) and leached fiberglass filaments
(Hitco or Haveg) or hybrid combinations thereof.
The high temperature resistant refractory fabric
13 may optionally be coated with a polymer coating such as
a silicone rubber, a neoprene rubber or a fluorinated
elastomer. The polymer coating serves to hold the yarns
firmly in place during assembly and provides an abrasion
resistant coating for the fabric 13 and provides protection
to the fabric during shipping, storage and deployment. A
particularly preferred coating for the present invention is
Neoprene GN (duPont), which is applied to the fabric 13 at
a coating weight of 0.16 kg/m2. The coating solution is
applied by dip coating the yarn while leaving the mesh
interstices substantially open. The fabric 13 is there-
after allowed to dry and cure at a temperature of 160C
before the fabric is incorporated into the boom. It will
be appreciated that the polymer coating, when within areas
exposed to the heat of combustion of the spilled oil, will
be burned off but it will have served its processing and
protection functions. Fabric 13 retains its high
temperature characteristics even without polymer coating.
Heat insulative spacer 14, may be 3M Macrolite
ceramic spheres or Pyrofoam ceramic spheres contained in a
spacer roll of knitted 304 stainless steel wire mesh. The
spacer is constructed by utilizing a 196 cm long and 107 cm
wide piece of mesh tubing and fastening seams alternately
spaced 7.6 cm and 10.2 cm apart using stainless steel
2(~37~318
--7--
sewing thread or wire (2 stitches/cm) or stainless steel
staples (l staple/2.5 cm). A total of 22 such seams are
produced thus generating 11 cells 14. Cutting along the
upper edge opens the cells and the 10.2 cm cells are filled
with ceramic spheres. The spheres are impermeable to water
and other fluids and, being a true ceramic, are functional
at extremely high temperatures. The sphere's outer surface
can be altered to provide other physical and chemical
properties. Pyrofoam ceramic spheres or granules are
preferred and are available from High Temperature
Insulation Materials, Route 14, Box 2337A, Kennewick, WA
99337. Other wire meshes such as inconel or galvanized
steel or high temperature refractory fabrics are also
satisfactory for spacer 14. The empty and filled cells are
then rolled into a heat insulating spacer around the
flotation core 15 and secured.
High temperature resistant flotation core 15 is a
20 cm diameter by 60 cm long closed cell foam log 18
wrapped in a knitted wire mesh 19 and preferably covered by
an oil resistant, heat reflecting and heat conducting metal
foil 20. It is contemplated that the foil 20, however, may
be positioned adjacent the core 15 and both covered by the
wire mesh 19. Foam log 18 may be a glass foam (such as
Foamglas cellular foam available from Pittsburg Corning) or
borosilicate ceramic foam (available from Thorpe Products)
or composites thereof. Glass foam is preferred because of
cost and availability. A closed, hollow metal container
could also be used, but because of weightJ cost and
possible explosive hazard is not desirable. Knitted wire
mesh 19 may be stainless steel, inconel, steel, galvanized
steel or alloys thereof. A preferred knitted wire mesh is
304 stainless steel (available from Metex Corporation)
having a wire diameter of about 230 micrometers with
knitted opening sizes corresponding to a density of 60.
Metal foil 20 is 50 micrometer thick stainless steel foil.
Other heat reflective and heat conductive metal foils would
be suitable. Since the metal foil does not provide a
-8- 2Q~ . 918
sealed envelope, air pressure build-ups are avoided.
Useful flotation cores have been produced without metal
foil 20, however it does serve to stop the flow of oil from
passing through the boom.
Boom 10 is fabricated by layerwise assembling a
composite of outer layer 11, first underlayer 12, second
underlayer 13 and heat insulative spacer 14 in registration
over flotation core 15. The thus formed composite
structure is unified by sewing along line 21 using a high
temperature resistant, ceramic thread, stainless steel
thread or suitably spaced mechanical fasteners. If
desired, the outer layer 11 could also be sewn together
along lines 22 providing a ballast chain pocket 17. In
view of the fact that seam lines 22 are below water during
lS boom use, they are preferably produced by using heavy duty
nylon.
To evaluate the utility of oil boom 10 under
simulated use conditions, six 30 cm diameter booms with a
30 cm skirt were coupled together into a circular shape. -
The circular test boom was then placed into a 3 m diameter
(1 m deep) steel tank which was filled with a mixture of 90
kilograms of salt added to 2300 liters of water to simulate
ocean salt water. A crude oil fire was simulated by pump-
ing approximately 3840 liters of heptane through a 2.5 cm
diameter pipe at a rate of about ll.S liters per minute
over a six hour period to the center of the boomed area in
the test tank. A 5 mph wind was blowing during the test.
Thermocouples were attached to the crown of the booms and
to a steel stand in the center of the containment area.
The boom performed excellently to contain the burning fluid
which reached temperatures as high as 1280C. The most
impressive performance characteristic was that the boom
maintained a freeboard (percentage of surface area above
the water line) of 70% before, during and after the fire
test.
A comparative high temperature oil containment
boom was constructed according to the teaching of patent
7918
application U.S. Serial No. 103,268, and also assigned to
the assignee of the present application, wherein a cellular
flotation core is utilized was similarly tested as above.
The comparative boom had a freeboard of 66~ before the fire
test which decreased during the test and after the fire
test had a freeboard of only 33%.
The particulars of the foregoing description are
provided merely for purposes of illustration and are
subject to a considerable latitude of modification without
departing from the novel teachings disclosed therein.
Accordingly, the scope of this invention is intended to be
limited only as defined in the appended claims, which
should be accorded a breadth of interpretation consistent
with this specification.
